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Velan ’ s Securaring™ gold-plated gasket incorporates these advantages while also addressing a common issue in gasket design . Its unique rib profile , securely positioned between the valve body and bonnet , prevents gasket rocking . This feature is critical as it ensures even distribution of sealing forces across the gasket surface . Uneven loading , a common problem with conventional gaskets , can lead to valve body leakage , compromising both safety and efficiency .
The implementation of such advanced gasket technologies goes beyond mere component improvement . It represents a systemic approach to enhancing the overall reliability and safety of hydrocracking units . By minimizing the risk of leaks and extending maintenance intervals , these gaskets contribute to increased operational uptime and reduced lifecycle costs .
Velan SecuraringTM pressure-energized goldplated gasket
Automation in Residue Hydrocracking Units
Residue hydrocracking units in oil refining involve many interacting components : valves , purge systems , heat tracing systems and reactors . Managing these operations by hand is difficult , error-prone , and can put workers at risk . For these reasons , refineries use Programmable Logic Controllers ( PLCs ) and control panels to automate these processes . Automation in hydrocracking units offers several benefits : 1 . Precision and accuracy : Automated systems control valves , purging and heating cycles more accurately than manual operation . This reduces errors that could affect product quality or safety .
2 . Safety : PLCs can detect unusual conditions quickly and trigger alarms or shutdowns to prevent accidents .
3 . Efficiency : Automated control adjusts operational settings to reduce downtime and improve unit efficiency .
4 . Data logging and analysis : PLCs record operational data , which helps with monitoring , analysis , maintenance planning and process improvements .
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These automation systems play a crucial role in enhancing the safety , efficiency and reliability of residue hydrocracking units .
PLC-controlled Systems in Residue Hydrocracking
Programmable Logic Controllers ( PLCs ) are essential in managing the complex operations of residue hydrocracking units .
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• Safety interlocks : These systems prevent valves from operating under unsafe conditions , avoiding hazards like over-pressurization or improper chemical mixing .
• Real-time monitoring : Continuous tracking of valve positions helps quickly identify and address any issues .
2 . Purge system management
• Automated purging : PLCs control purging cycles , ensuring thorough removal of unwanted gases or liquids from the system .
• Feedback-based adjustments : Sensors provide real-time data on purging effectiveness , allowing for necessary adjustments .
• Safety integration : Purge systems connect with overall safety protocols , automatically triggering purges during anomalies or emergency shutdowns .
3 . Heating cycle control
• Temperature regulation : PLCs monitor and adjust heating elements to maintain optimal temperatures for efficient reactions .
• Energy management : Automated control helps optimize energy use , balancing operational costs with process efficiency .
• Thermal safety measures : Temperature sensors and feedback systems prevent overheating , protecting equipment and personnel .
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Velan Hexashield™ thermal sleeve undergoing finite element analysis
4 . Control panel features
• Operator interfaces : Control panels typically feature user-friendly interfaces for easy monitoring and control .
• Performance analytics : Many systems include tools for analyzing performance data , helping identify trends and potential issues .
• Remote access capabilities : Some setups allow for remote system access , enabling quick responses to operational changes .
• Data management : Continuous data logging supports detailed analysis , reporting and regulatory compliance .
Conclusion
Advancements in valve technology are playing a crucial role in enhancing the reliability , efficiency and safety of residue hydrocracking reactors . These complex systems operate under extreme conditions , necessitating continuous innovation in materials , design and control systems .
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Key developments in the field include :
1 . Thermal protection solutions that mitigate the effects of rapid temperature changes on valve components .
2 . High-performance gaskets utilizing noble metal plating to improve corrosion resistance and sealing capabilities .
3 . Advanced automation systems that provide precise control , real-time monitoring and predictive maintenance capabilities
Velan has contributed to these advancements with innovations such as the Hexashield™ thermal sleeve and Securaring™ gold-plated body seal gaskets . Such technologies , coupled with digital solutions for real-time monitoring and predictive maintenance , provide a robust framework for optimizing reactor performance .
These innovations collectively contribute to :
• Improved reactor performance and product quality
• Extended equipment lifespan and reduced maintenance requirements
• Enhanced safety protocols and risk mitigation
• Increased operational efficiency and reduced downtime
As the refining industry faces growing challenges , including processing heavier crude oils and meeting stricter environmental regulations , these technological advancements will be essential .
The ongoing collaboration between valve manufacturers like Velan , refineries and research institutions will be
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crucial in driving further innovations to address the complex needs of residue hydrocracking processes .
ABOUT THE AUTHORS
Duke Tran , P . Eng MBA , is the Executive Vice- President of Product Innovation and Technology at Velan . With 35 years in the valve industry , Duke has led engineering teams at major global manufacturers and held executive roles in sales , marketing , and business development . He holds 37 US patents in flow control technologies , reflecting his commitment to advancing fluid handling systems .
Luc Vernhes , Ph . D , P . Eng ., is the Director of Business Development at Velanwhich he joined in 2003 . He previously led Velan ’ s Innovation , R & D , and Technology team and the metal-seated ball valve design team . Luc chairs the Canadian Mirror Committee ISO / TC 153 , holds a PhD in Engineering Physics and a Master ’ s in Mechanical Engineering , and is a licensed Mechanical Engineer in Québec . He has six US patents and has published approximately 15 peer-reviewed papers .
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These systems offer precise control , enhanced safety and improved efficiency . Here ’ s an overview of key applications : |
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1 . Valve control
• Sequential operation : PLCs manage valve sequences , ensuring correct material flow throughout the process . This includes precise valve timing and maintaining proper pressure and flow rates .
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3D-printed model of a Velan Hexashield™ patented thermal sleeve |